MEGA-PURE®One Liter Water Still

OPERATION MANUALAND PARTS LIST

SERIES 798

LT798X1 • 7/31/02

Model Number VoltageA440266 120V Without BottleA440267 120V With BottleA7981 240V Without BottleA7982 240V With Bottle

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Important InformationThis manual contains important operating and safety information. You must carefully read and understand thecontents of this manual prior to the use of this equipment.

Water purification technology employes one or more of the following: chemicals, electrical devices, mercuryvapor lamps, steam and heated vessels. Care should be taken when installing, operating or servicingBarnstead products. The specific safety notes pertinent to this Barnstead product are listed on page 4.

Figure 1 MEGA-PURE One Liter Still

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Table of Contents

Important Information....................................................................................................................................2Table of Contents..........................................................................................................................................3Safety Information ........................................................................................................................................4

Alert Boxes ............................................................................................................................................4Warnings ................................................................................................................................................4

Introduction ..................................................................................................................................................6Unpacking ....................................................................................................................................................7Installation and Service Requirements ........................................................................................................8

Location of Unit ......................................................................................................................................8Service Requirements ............................................................................................................................8Power ....................................................................................................................................................9Water Supply Requirements ..................................................................................................................9Drain ....................................................................................................................................................10

Initial Assembly ..........................................................................................................................................10Feedwater Connections ..............................................................................................................................11

Tap Water Boiler Feed..........................................................................................................................11Pretreated Boiler Feed ........................................................................................................................12Demineralizer Treated Boiler Feed ....................................................................................................13In-House Treated Boiler Feed ............................................................................................................14

Still Output Connections ............................................................................................................................16Storage Bottle Installation ....................................................................................................................16Automatic Collection System Installation ............................................................................................17

Operation ....................................................................................................................................................18High Temperature Cut-off Switch ........................................................................................................19

Maintenance and Servicing ........................................................................................................................20Cleaning ..............................................................................................................................................20Troubleshooting....................................................................................................................................21General ................................................................................................................................................21Electrical ..............................................................................................................................................23Still Troubleshooting ............................................................................................................................23Automatic Collection System Troubleshooting ....................................................................................24

Parts List ....................................................................................................................................................25Parts arranged by Exploded View key number....................................................................................25

Exploded View ............................................................................................................................................26Wiring Diagram ..........................................................................................................................................27Ordering Procedures ..................................................................................................................................28One Year Limited Warranty ........................................................................................................................32

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Your Barnstead MEGA-PURE One Liter Water Still has beendesigned with function, reliability, and safety in mind. It is yourresponsibility to install it in conformance with local electricalcodes. For safe operation, please pay attention to the alertsignals throughout the manual.

WarningsTo avoid electrical shock, always:

1. Use a properly grounded electrical outlet of correctvoltage and current handling capacity.

2. Ensure that the equipment is connected to electri-cal service according to local and national stan-dards. Failure to properly connect may create afire or shock hazard.

3. Do not mount the MEGA-PURE One Liter WaterStill directly over equipment that requires electricalservice. Routine maintenance of this unit mayinvolve water spillage and subsequent electricalshock hazard if improperly located.

4. Replace fuses with those of the same type and rat-ing.

5. Disconnect from power supply before servicing.

6. Do not connect unit to electrical service untilinstructed to do so.

To avoid personal injury:1. Do not use in the presence of flammable or com-

bustible materials; fire or explosion may result.This device contains components which may ignitesuch materials.

2. Wear eye and hand protection when using acid forcleaning, as acid spattering may occur.

3. Use this device with water feed only. Failure tocomply with the above could result in explosionand personal injury.

4. Ensure all piping connections are tight to avoidleakage of chemicals.

Safety Information

WarningWarnings alert you to a possibility ofpersonal injury.

CautionCautions alert you to a possibility ofdamage to the equipment.

NoteNotes alert you to pertinent factsand conditions.

Alert Signals

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5. Always depressurize chemical lines before disas-sembly.

6. To avoid exposure to chemical fumes, ensure ade-quate ventilation when using chemicals for clean-ing.

7. Follow carefully the manufacturers’ safety instruc-tions on labels of chemical containers and MaterialSafety Data Sheets (M.S.D.S.).

8. “Caution - Hot Surface. Avoid Contact.” Glass por-tions of still become hot when still is operating. Toavoid burns, do not touch hot glass.

9. Refer servicing to qualified personnel.

C. To ensure safe mounting:1. Wall composition and construction, as well as fas-

tener type, must be considered when mountingthis unit. The mounting surface and fastenersselected must be capable of supporting a minimumof 60 lbs.; inadequate support and/or fastenersmay result in damage to mounting surface and/orequipment. If you are unsure of mounting surfacecomposition, condition and construction, or correctfasteners, consult your building maintenance groupor contractor.

SAFETY INFORMATION

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Your Barnstead MEGA-PURE One Liter Water Still is a com-pact, all glass unit with Teflon® connectors designed to pro-vide 1.4 liter per hour of high purity distilled water. The prod-uct water is non-pyrogenic per USP XIX. Resistivity will begreater than 1.0 megohm-cm at the condenser outlet usingmost tap water as feed. This water still can be used as a dis-crete unit or with customer supplied pretreated water. It canalso be connected to the Barnstead Automatic CollectionSystem for completely automatic operation.

Your MEGA-PURE One Liter Water Still allows you toreplace tap water boiler feed with demineralized, distilled orR.O. water for low maintenance operation and high purity dis-tillate. Distilled water storage can be easily handled in theoptional 6-liter polyethylene or 9-liter Pyrex brand storagebottle. Either fits conveniently inside the water still cabinetand dispenses distilled water through a valve which is acces-sible at the front of the still.

Choice of a location for your MEGA-PURE One Liter WaterStill is primarily a matter of convenience. This unit may belocated on a bench or wall mounted.

Your MEGA-PURE One Liter Water Still is rated at either120 volts, 50/60 Hz, 1000 watts, single phase or 240 volts,50/60 Hz, 1000 watts, single phase. This unit requiresapproximately 11 to 15 liters per hour of cooling water.

The cabinet and glassware are protected against damagefrom overheating by a thermal switch.

Introduction

WarningUse a properly grounded electrical outletof correct voltage and current handlingcapacity.

Ensure that the equipment is connectedto electrical service according to localand national standards. Failure to prop-erly connect may create a fire or shockhazard.

Do not mount the MEGA-PURE OneLiter Water Still directly over equipmentthat requires electrical service. Routinemaintenance of this unit may involvewater spillage and subsequent electricalshock hazard if improperly located.

Do not connect unit to electrical serviceuntil instructed to do so.

NoteOperation of the still at a voltageless than the stated voltage willcause a drop in still output.

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Tools required: Diagonal cutting pliers.

1. Remove parts box and still from shipping cartonand place on workbench.

2. Check glassware inside the main cabinet fordamage. Check parts in the accessory box fordamage. Identify any broken or damaged partsand report them to your dealer immediately.

Refer to Figure 1 (page 2) for the following step:3. Using diagonal cutting pliers, cut and remove

the five (5) plastic shipping ties. The shippingtie locations are: Two (2) on the condenser "B",two (2) on the boiler "I", and one (1) on the trap"N."

Unpacking

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Installation and ServiceRequirements

Location of UnitChoice of location for the MEGA-PURE One Liter Water Stillis primarily a matter of convenience as long as the servicerequirements, listed on the next page, are met.

A. The still may be bench or wall mounted. Allow 4"-6" clearance at the sides and top for circulation ofambient air to prevent buildup of heat in the cabi-net.

B. Unit Dimensions: 18" wide x 10" deep x 34" high.

C. Wall Mounting: The still is supplied with slottedmounting holes located 16" on center in the rear ofthe cabinet and 22 7/8" from the bottom. The weight of the unitwith a full storage bottle is 45-60 lbs.

Service Requirements

Power Your water still is supplied with a power cord (5 feet long) andplug. The plug on the 120V unit requires a standard NorthAmerican 120V, 15A, 3-prong receptacle. The plug on the240V unit requires a standard European 240 volt receptacle.(See Figure 2.) If you do not have the required receptacleavailable within 5 feet of your still, a certified electricianshould install one in accordance with local and national stan-dards. As an alternate method of power supply for a 240 voltunit, your electrician may remove the supplied plug and wirethe cord to a 15A-250V breaker box. (See Figure 3.)

Water Supply RequirementsBarnstead recommends one of the following options for sup-plying water to operate your MEGA-PURE One Liter WaterStill.OPTION #1

A single, untreated cold water supply. The supply must becapable of providing a minimum of 4 gallons (15 liters) perhour at a pressure of 20-100 psi and be located within 4 feet(1.2 meters) of the MEGA-PURE One Liter Water Still. Youmust provide a shut off valve and reducer as shown in Figure4.

WarningDo not mount the MEGA-PURE OneLiter Water Still directly over equip-ment that requires electrical service.Routine maintenance of this unitmay involve water spillage and sub-sequent electrical shock hazard ifimproperly located.

Wall composition and construction,as well as fastener type, must beconsidered when mounting thisunit. The mounting surface andfasteners selected must be capa-ble of supporting a minimum of 60 lbs.; inadequate supportand/or fasteners may result indamage to mounting surfaceand/or equipment. If you areunsure of mounting surface com-position, condition and construc-tion, or correct fasteners, consultyour building maintenance groupor contractor.

WarningEnsure that the equipment is con-nected to electrical service accord-ing to local and national standards.Failure to properly connect may cre-ate a fire or shock hazard.

Do not connect unit to electrical ser-vice until instructed to do so.

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Figure 2 240 Volt Receptacle

Figure 3 15A - 250V Breaker Box

Ground

LineLine

With Option #1, approximately 4 gallons of untreated waterwill be used per hour in the cooling section of the still, 1 gal-lon of this water will be used as boiler feed. Water connec-tions are discussed on pages 13-14.OPTION #2

An untreated cold water supply plus a source of RO, dem-ineralized or previously distilled water. The untreated supplymust be capable of providing a minimum of 4 gallons (15liters) per hour at a pressure of 20-100 psi and be locatedwithin 4 feet (1.2 meters) of the water still. The treated supplymust be capable of providing 1 gallon (3.75 liters) per hourand be located within 4 feet of the water still. You must pro-vide a shut-off valve and reducer at each water supply (seeFigure 4). In addition you will require the optional double sole-noid valve kit (Catalog No. RY798X2A (120V) or 440236(240V)).

With Option #2, approximately 4 gallons of untreated waterwill be used each hour for cooling. The second (treated)water supply of 1 gallon per hour will be used as boiler feed.Water connections are discussed on pages 14-18.

DrainAn open or atmospherically vented drain located lower thanthe still is necessary to allow for gravity flow. Barnstead sup-plies a 5 foot length of 1/2" I.D. vinyl tubing for the drain.Additional tubing may be purchased from your laboratorydealer.

INSTALLATION AND SERVICE REQUIREMENTS

Load(Blue Wire)

Line Ground

Load Ground(Green Wire)

Line

Load(Brown Wire)

WaterSupply

Reducer

2" - 3" Length of pipewith 1/8" N.P.T.

Figure 4 Shut-off Valve

NoteThe double solenoid valve kit is not neededif you are using a MEGA-PURE D1 or D2deionizer for pretreatment.

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Tools required for assembly: 7/16" open end wrench, diagonalcutting pliers, common screwdriver.

1. Unwrap the condenser “B” and thoroughly flush allof the salt out.

2. Reattach the condenser “B” to the still and thenattach the two Teflon connectors “D” and “P” to thecondenser “B” as shown in Figure 1.

3. Check orientation of trap "N." If it is not level or tilt-ed back toward the boiler as shown in Figure 1,move the condenser "B" up in its bracket. This willtilt trap as shown in Figure 1.

4. Remove the packing material and rotate tube "L"into the constant level chamber of boiler "I" asshown in Figure 1.

5. Unpack the Vycor® immersion heater "M" andcheck the voltage rating on the top cap. It shouldagree with the voltage of your power supply. If itdoes not, contact your dealer and order the correctheater.

6. Insert the immersion heater into the top opening ofboiler "I" as shown in Figure 1.

7. Thread the heater plug and cord through the largehole above the boiler "I," then back through thehole below the control box "H." Plug heater pluginto the receptacle on the bottom of the controlbox. The plug is twist-lock type and requires 1/4clockwise turn to lock in place.

Initial Assembly

Figure 5 Control Bottom Connections

Solenoid PowerReceptacle

Heater PowerReceptacle

MEGA-PUREDeionizerControlReceptacle

ACS ControlReceptacle

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This still always uses tap water for cooling the steam in thecondenser. However, you have the option of feeding yourboiler with higher purity pretreated water, thereby reducingthe need to drain and clean your boiler.

If you will be using tap water as your boiler feedwater, pro-ceed to the Tap Water Boiler Feed section. If you will beusing a supply of distilled, deionized or reverse osmosiswater as your boiler feed, proceed to the Pretreated BoilerFeed section.

Tap Water Boiler FeedSee Figure 6

1. Install a customer supplied shutoff valve onto yourtap water source. Thread the solenoid valve ontoyour customer supplied shutoff, with the sidemarked “in" toward the shutoff.

2. Install the supplied fitting to the “out” side of thesolenoid valve. Connect the 5/16" I.D. tubing (fromthe condenser) to this fitting.

3. Route 3/8" I.D. vinyl drain tubing to an atmospheri-cally vented drain.

Feedwater Connections

Figure 6 Tap Water Feed Only

NoteBarnstead strongly recommends thatyou install the optional flowmeter(Catalog Number 440092) into yourfeedwater line(s). This will allow youto control the flow of water to yourstill easily and precisely.

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4. Plug the solenoid valve power cord (not shown)into the receptacle on the bottom of the control box"H." (See Figure 5.)

5. Go to the Still Output Connections section to com-plete your still's setup.

Pretreated Boiler FeedWhen a supply of distilled, deionized or reverse osmosiswater is to be used as boiler feed, first revise the still connec-tions as follows:

1. Remove boiler fill tube "O" from still and set aside.

2. Locate the 3/8" I.D. x 44" long vinyl tubing and onebarbed tee (3/8" I.D. x 3/8" I.D. x 3/8" I.D.) in theparts box.

3. Install one end of the vinyl tubing to the coolingwater outlet located on the top right of the con-denser "B" (where boiler fill tube "O" wasattached). Route the other end through the cabinetand down the back as shown in Figure 7.

4. Cut the 3/8" I.D. vinyl drain tubing and install thebarbed tee. Connect the 3/8" I.D. vinyl tubing fromcondenser to the barbed tee. Push the vinyl tubingall the way onto the tee to assure a leak free seal.

5. Route the drain tubing to an atmospherically vent-ed drain.

If you will be using a MEGA-PURE D1 or D2 demineralizer toprovide pretreated boiler feed, go to the DemineralizerTreated Boiler Feed section. If you will be using an "in-house"source of pretreated water for boiler feed, go to the In-HouseTreated Boiler Feed section.

FEEDWATER CONNECTIONS

Figure 7 Tubing Connections

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Demineralizer Treated Boiler Feed See Figure 8. (Must have optional still adapter kit: CatalogNo. 440376)

1. Install a customer supplied shutoff valve onto yourtap water source. Thread the solenoid valve ontoyour customer supplied shutoff, with the sidemarked “in" toward the shutoff.

2. Install the fitting supplied with the still adapter kitinto the “out” side of the solenoid valve. Connectthe 1/4" O.D. tubing (from the demineralizer) tothis fitting.

3. Cut the 1/4" O.D. tubing (from last step) at a con-venient point and install the tee from the stilladapter kit (Catalog No. 440376).

4. Connect a length of 1/4" O.D. tubing to the thirdarm of the tee. Connect the 1/4" O.D. to 3/8" I.D.adapter to the free end of this length of 1/4" O.D.tubing. Connect the 5/16" I.D. tubing (from the condenser) to thisadapter.

5. Locate boiler fill tube "L." Connect 7/16" I.D. vinyltubing from demineralizer output to end of boiler filltube. Route as shown and install clip "S" to sup-port the tubing.

FEEDWATER CONNECTIONS

Figure 8 Deionizer Feed

NoteIf using the optional flowmeter,install it at this point instead of theadapter.

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6. Route 3/8" I.D. vinyl drain tubing to atmospherical-ly vented drain.

7. Plug solenoid valve power cord (not shown) intoreceptacle in control box "H."

8. Plug still adapter kit cable into right side of dem-ineralizer and receptacle in control box "H."

9. Go to the Still Output Connections section on page19 to complete the setup of your still.

In-House Treated Boiler Feed See Figure 9. (Must have optional double solenoid valves:Catalog No. 440236 (240V), RY798X2A (120V))

1. Install customer supplied shutoff valves onto yourtap water source and your in-house treated watersource. Thread the solenoid valves onto your cus-tomer supplied shutoffs, with the sides marked “in"toward the shutoffs.

2. Install the supplied 5/16" fitting to the “out” side ofthe solenoid valve on your tap water source.Connect the 5/16" I.D. tubing (from the condenser)to this fitting.

FEEDWATER CONNECTIONS

Figure 9 In-house Treated Feed

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3. Connect the 3/8" fitting and 3/8" I.D. vinyl tubingfrom the double solenoid valve kit to the “out” sideof the solenoid valve on your treated water supply.

4. Locate the boiler fill tube "L." Connect 3/8" I.D.from treated water supply solenoid to the end ofthe boiler fill tube. Route as shown and install clip"S" to support the tubing.

5. Route the 3/8" I.D. vinyl drain tubing to an atmos-pherically vented drain.

6. Plug the solenoid valve power cord (not shown)into the receptacle in control box "H" (See Figure5.)

7. Go to the Still Output Connections section on page19 to complete the setup of your still.

FEEDWATER CONNECTIONS

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If you are using one of the optional Storage Bottles, go to theStorage Bottle Installation section. If you are connecting yourstill to an Automatic Collection System, go to the AutomaticCollection System Installation section.

Storage Bottle InstallationTo install the optional 6 or 9 liter storage bottle inside the oneliter still cabinet, first locate the following parts in the storagebottle parts box:

Product delivery tube "F"Teflon Connector "E"20" length of 1/2" vinyl tubingPlastic tee (1/2 X 1/2 X 1/2)

1. Place storage bottle (with product delivery tube "F"installed) inside still cabinet below condenser "B."Connect product delivery tube to condenser withTeflon connector "E."

2. Locate plastic tee (1/2 x 1/2 X 1/2) and 20" lengthof 1/2" vinyl tubing in parts box. Connect to bottleoverflow tubulation and drain as shown in Figure10 below.

Still Output Connections

NoteThe storage bottles do not automati-cally control the still.

Figure 10 Storage Bottle Installation

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STILL OUTPUT CONNECTIONS

Automatic Collection SystemInstallationBefore connecting your MEGA-PURE One Liter Water Still tothe Barnstead Automatic Collection System, move the still toits final location.

1. Locate ACS tube "Q" and Teflon connector "E" inthe ACS parts box. Locate distillate outlet tube(TU798X1) in the still parts box. Assemble to tub-ing from collection system as shown in Figure 11.

2. Plug input jack from ACS into ACS receptacle onbottom of still control box "H." (See Figure 5)

Figure 11 Complete System Layout (Not to scale)

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Plug electrical power cord into appropriate receptacle.Refer to Figure 1, page 2 for referenced locations.

1. Close drain clamp "G" on bottom of boiler "I."

2. Open valve at tap water source and treated watersource if so installed.

3. Switch on the main power breaker on control atcustomer power source.

4. Push “Water” switch on control box "H". Greenindicator will light and solenoid will open. Allowboiler to fill.

5. Push “OPERATE” switch. Indicator will light andheaters will come on.

6. Allow the still to operate for 15-20 minutes. Formaximum volume of distillate, increase the flow ofcooling water to the point where only a slight wispof steam is visible at the condenser vent "A." If youare using a separate source of pretreated water foryour boiler feed, adjust the boiler feed flow so thata constant overflow from the boiler is maintained.

7. Your MEGA-PURE One Liter Water Still shouldnow be operational. Run the still for 4-5 hours tocleanse itself before collecting water for use.

8. To shut your water still off push the OFF switch.This will shut the water supply and the heaters off.

If any difficulties are encountered in operating this water still,check all operating and assembly steps to be sure the stillwas assembled and is being operated correctly. If the difficul-ty still exists, consult the Troubleshooting section of this man-ual.

Operation

WarningUse a properly grounded electricaloutlet of correct voltage and currenthandling capacity.

Ensure that the equipment is con-nected to electrical service accord-ing to local and national standards.Failure to properly connect may cre-ate a fire or shock hazard.

Do not use in the presence of flam-mable or combustible materials; fireor explosion may result. This devicecontains components which mayignite such materials.

Use this device with water feed only.Failure to comply with the abovecould result in explosion and person-al injury.

“Caution - Hot Surface. AvoidContact.” Glass portions of stillbecome hot when still is operating.To avoid burns, do not touch hotglass.

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High Temperature Cut-off SwitchYour MEGA-PURE One Liter Water Still is protected againstoverheating by a thermal switch located in the control box atthe right hand side of the boiler. Should the boiler overheat,the switch will open causing the heater and water supply toshut off. When the boiler cools (5-15 minutes), the switch willreset automatically, but the still will have to be restarted bythe operator. When unit has cooled, press the “WATER”switch and then the “OPERATE” switch to restore normaloperation. Check boiler occasionally for proper water level.

OPERATION

NoteIf you are feeding an ACS with yourstill, note that when the ACS is full, itwill signal the still to shut down.During this shut-down, the heaterand the water supply will both shutoff and the front panel lights on thestill will be extinguished. This normaloperation can mimic the effects ofan overheating boiler, but does notrepresent any problem with the still.

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CleaningFor top performance and efficiency, the MEGA-PURE OneLiter Water Still should be kept clean and free of scale. It isrecommended that the boiler be drained and refilled withfresh water daily to flush the boiler of the concentration ofcontaminants from the previous day’s run.

When using untreated boiler feed, cleaning is recommend-ed after every 15-20 hours of operation. The unit should becleaned with a hydrochloric acid solution. This is done as fol-lows:

1. Push unit “OFF” switch.

2. Disconnect output tubing at condenser "B" fromcollection vessel and temporarily place a beakerunder condenser outlet.

3. Drain boiler by opening clamp "G." Close clamp"G" after boiler has completely drained. Refill boil-er.

4. Use the spare pinch clamp from the parts box toshut off overflow tube from constant level chamber"K" as close as possible to overflow stem.

5. Carefully pour approximately 260 ml. of 10%hydrochloric acid solution into top of constant levelchamber "K."

6. Wait approximately 10 minutes or until residue dis-appears. If additional cleaning is required, drainboiler down 1 inch and turn unit on for a few min-utes until residue disappears. Do not boil. Turn thestill off.

7. Carefully drain the unit, remove clamp from over-flow tube and refill with fresh water. Drain boiler,refill with fresh water and operate for 30 minutes.Reconnect tubing from collection vessel to con-denser "B."

Maintenance and Servicing

WarningDisconnect from the power supplybefore servicing.

Wear eye and hand protection whenusing acid for cleaning, as acid spat-tering may occur.

Ensure all piping connections aretight to avoid leakage of chemicals.

Always depressurize chemical linesbefore disassembly.

To avoid lung injury or suffocation,ensure adequate ventilation whenusing chemicals for cleaning.

Follow carefully the manufacturers’safety instructions on labels ofchemical containers and MaterialSafety Data Sheets (M.S.D.S.).

Refer servicing to qualified person-nel.

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Troubleshooting

General

MAINTENANCE AND SERVICING

Problem Causes SolutionLeaks. The most common leak is one

occurring in the vinyl draintubing. Hot water causessoftening and pulling loose atthe plastic barbed connectors.

Runs of vinyl tubing should besupported to reduce the pullon the plastic connectors.Small clamps may be used tofirmly hold the vinyl tubing.

Rough Boiling. Rough boiling is the result ofalkali attack to the matte finishon the heaters. The mostcommon cause is using waterpretreated with NaCIregenerated water softeners.

Remove heater and lightlyroughen surface with 150 gritsandpaper.

Scale Build-up. A brownish-white scale in theboiler indicates that the boilerrequires cleaning.

Clean boiler per cleaninginstructions. Scale should notbe allowed to accumulate asheaters may be damaged.

Heater Failure.

Heater failure due to scalebuild-up or alkali attack willnot be replaced underwarranty.

Short life on Vycor®immersion heaters can usuallybe attributed to use of waterpretreated with NaCIregenerated water softenersor excessive scale buildup.

Softened water used as aboiler feed causes aconcentration of sodium ionsand alkaline attack of theVycor® glass. Rough boilingwill be the first indication ofalkaline attack. At failure, theheaters will usually pinholeand water entering will shortout the element.

Scale build-up will occur whenboiler feed is not beingdeionized.

If softened water must beused, heater life can beprolonged somewhat bydraining boiler every day.

When using the still without adeionizer, scale build-up mustbe removed after every 15-20hours of operation (see"Cleaning Instructions").Failure to do so will causeheaters to build up heatinternally and fail or causeglass envelope failure.

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General (con't)

Problem Causes SolutionSteam at Condenser Vent. A slight wisp of steam exiting

at the condenser vent isnormal. Gases in the steam arealso being removed.

If there is an excessive amountof steam leaving thecondenser vent, increase thecooling water flow rate.

No Steam at Condenser Vent. If no steam is visible, decreasecooling water flow rate.

Water Pressure Variations. Pressure fluctuations in yourtap water line will cause erraticflow in cooling water and maycause water level in boiler todrop.

Have a plumber install apressure regulator in your tapwater line and regulate to 20-25 psi.

Output Less Than 1 Liter/Hr. Heaters will produce in excessof 1 L/hr. of distilled waterwhen run at the rated voltage.At lower voltages, output willdrop accordingly.

Also see "Steam atCondenser Vent" as excesssteam at this point will reduceoutput.

MAINTENANCE AND SERVICING

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ElectricalBefore troubleshooting can begin, the problem component must be determined. That is accomplished as follows:

1. Disconnect the demineralizer and ACS jacks from the still control box and attempt to run the still. If stillfails, see “Still Troubleshooting.” If still runs, go to step #2.

2. Connect the demineralizer input jack back up to the still control box and attempt to run the still. If stillfails to run see “Demineralizer Troubleshooting” (in the Demineralizer Manual). If still runs, see“Automatic Collection System Troubleshooting.”

Still Troubleshooting

OPERATION

Problem Cause Solution

Heaters and water will not stayon.

Hi-temp cut-off switch open. Remove control box andreplace switch.

Heater not boiling, heater lighton.

Heater element burnt out. Check heater (13.9Ω for 120Vor 55.9Ω for 240V) andreplace.

Heater not working. Heater element burnt out. Replace heater.Water will not come on, butlight works.

Solenoid valve not working. Check plug for connection.Replace solenoid valve.

No lights in switches. ACS full; still off.

Indicator lights burnt out.

This is normal operation whenthe still is used to feed anACS. When water level in theACS dropps, still will reactivateand lights will come back onautomatically.

Replace switches (switcheswill operate without lights).

Fuse(s) blown. Heater shorted.

High voltage.

Check heater (13.9Ω for 120Vor 55.9Ω for 240V) andreplace.

Check input voltage againstheater rating. Correct.

Unit off, but water still flowing. Solenoid valve installedbackwards.

Solenoid valve stuck open.

Solenoid labeled "in" on inputside. Check.

Replace solenoid valve.

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Automatic Collection System Troubleshooting

MAINTENANCE AND SERVICING

Problem Cause SolutionWill not turn still on or off as itshould.

Float stuck.

Switch not working.

Input jack not plugged in.

Jack board defective.

Remove level control coverand free-up.

Replace switch.

Check and reconnect.

Replace jack board.

WarningReplace fuses with those of the same type and rating.

Parts ListAll replacement parts must be ordered through your laboratory dealer.

Parts arranged by Exploded View key number

Exploded View Figure 1 Item KeyKey Number Description Part Number

1 A Steam Vent Tubing TU674X62 C Boiler/Condenser Spring (set of 4) 4161043 B Condenser 4012034 P Teflon® Connector (3/8" I.D.) 4013985 Inlet Tubing TU674X76 D Teflon® Connector (1 5/32" I.D.) 4013977 N Steam Trap 4012028 O Boiler Fill Tube (Cond. to Conn.) 4012159 Teflon® Connector (3/8" I.D.) 40139810 L Boiler Fill Tube (Conn. to Boiler) 40121611 I Boiler 40120112 Constant Level Overflow Tubing TU674X313 G Boiler Drain Tubing Clamp 92791714 Boiler Drain Tubing TU674X215 Drain "T" 92732616 Drain Tubing TU674X117 H Electrical Control Box (120V) CN798X1A

Electrical Control Box (240V) CN798X2AF Distillate Outlet Tube - Tubing/Bottle TU798X2J Water, Operate, Off Switches SW745X1AM Vycor Immersion Heater, 120V-1000W 740880M Vycor Immersion Heater, 240V-1000W EL798X1BQ Distillate Outlet Tube - ACS TU798X1

Not Shown Electrical Control Box PC Board PC798X1ANot Shown Solenoid Valve (120V)* RY798X1ANot Shown Solenoid Valve (240V) 440093Not Shown Fuse (Buss Type ABC-12A, 250V) 410148Not Shown Hi-Temperature Cutoff Switch SWX150

Optional Accessories18 6-Liter Polyethylene Bottle 41396418 9-Liter Pyrex Brand Bottle 410535

Flowmeter Kit 440092Dual Solenoid Valve (120V) RY798X2ADual Solenoid Valve (240V) 440236

19 Connector** within electrical box CE798X1A*RY798X1A Solenoid Valve ( supplied with still)**CE798X1A #19 is shown in Figure 5

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Exploded View

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Wiring Diagram

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Please refer to the Specification Plate for the complete model number, serial number, and seriesnumber when requesting service, replacement parts or in any correspondence concerning thisunit.

All parts listed herein may be ordered from the Barnstead International dealer from whomyou purchased this unit or can be obtained promptly from the factory. When service or replace-ment parts are needed we ask that you check first with your dealer. If the dealer cannot handleyour request, then contact our Customer Service Department at 563-556-2241 or 800-553-0039.

Prior to returning any materials to Barnstead International, please contact our CustomerService Department for a “Return Goods Authorization” number (RGA). Material returned withouta RGA number will be refused.

Teflon is a registered trademark of the DuPont Company PYREX is a registered trademark of Corning, Inc. MEGA-PURE is a registered trademark of Barnstead International

Ordering Procedures

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Barnstead International (“BARNSTEAD”) warrants that if a product manufactured by Barnstead shall be free ofdefects in materials and workmanship for one (1) year from the first to occur of (i) the date the product is sold byBARNSTEAD or (ii) the date the product is purchased by the original retail customer (the “CommencementDate”). Except as expressly stated above, BARNSTEAD MAKES NO OTHER WARRANTY, EXPRESSED ORIMPLIED, WITH RESPECT TO THE PRODUCTS AND EXPRESSLY DISCLAIMS ANY AND ALL WARRANTIES,INCLUDING BUT NOT LIMITED TO, WARRANTIES OF DESIGN, MERCHANT ABILITY AND FITNESS FOR APARTICULAR PURPOSE.

An authorized representative of BARNSTEAD must perform all warranty inspections. In the event of a defectcovered by BARNSTEAD’s warranty, BARNSTEAD shall, as its sole obligation and exclusive remedy, provide freereplacement parts to remedy the defective product. In addition, for products sold by BARNSTEAD within the con-tinental United States or Canada, BARNSTEAD shall provide provide free labor to repair the products with thereplacement parts, but only for a period of ninety (90) days from the Commencement Date.

BARNSTEAD’s warranty provided hereunder shall be null and void and without further force or effect if there isany (i) repair made to the product by a party other than BARNSTEAD or its duly authorized service representa-tive, (ii) misuse (including use inconsistent with written operating instructions for the product), mishandling, conta-mination, overheating, modification or alteration of the product by any customer or third party or (iii) use ofreplacement parts that are obtained from a party who is not an authorized dealer of BARNSTEAD.

Heating elements, because of their susceptibility to overheating and contamination, must be returned to theBARNSTEAD factory and if, upon inspection, it is concluded that failure is due to factors other than excessivehigh temperature or contamination, BARNSTEAD will provide warranty replacement. As a condition to the returnof any product, or any constituent part thereof, to BARNSTEAD’s factory, it shall be sent prepaid and a prior writ-ten authorization from BARNSTEAD assigning a Return Goods Number to the product or part shall be obtained.

IN NO EVENT SHALL BARNSTEAD BE LIABLE TO ANY PARTY FOR ANY DIRECT, INDIRECT, SPECIAL, INCI-DENTAL, OR CONSEQUENTIAL DAMAGES, OR FOR ANY DAMAGES RESULTING FROM LOSS OF USE ORPROFITS, ANTICIPATED OR OTHERWISE, ARISING OUT OF OR IN CONNECTION WITH THE SALE, USEOR PERFORMANCE OF ANY PRODUCTS, WHETHER SUCH CLAIM IS BASED ON CONTRACT, TORT(INCLUDING NEGLIGENCE), ANY THEORY OF STRICT LIABILITY OR REGULATORY ACTION.

The name of the authorized Barnstead International dealer nearest you may be obtained by calling 1-800-446-6060 (563-556-2241) or writing to:

One Year Limited Warranty

2555 Kerper BoulevardP.O. Box 797Dubuque, Iowa 52001-0797Phone: 563-556-2241 or 800-553-0039Fax: 563-589-0516E-mail: mkt@barnstead.comwww.barnstead.com